Apparatus and method for conversion of solid waste into synthetic oil, gas, and fertilizer

ABSTRACT

A method of producing oil, gas, and ash fertilizer from a feedstock includes inputting the feedstock into a reaction chamber having a wall, and combusting the feedstock in the reaction chamber. An electrical current flow is induced between the reaction chamber wall and the feedstock so as to cause arcing in the feedstock within the reaction chamber. Ash reaction byproducts migrate downward through the reaction chamber onto ash support structure, which is substantially electrically isolated from the reaction chamber wall. Gas and liquid reaction byproducts migrate upward through the reaction chamber to an upper chamber by a partial vacuum in the upper chamber, and are evacuated therefrom. The oil and gas are then separated from the evacuated gas/liquid products, providing the oil and the gas products. The oil is refinable, the gas is high in energy content, and the ash fertilizer is high in nitrogen.

This application is a divisional of U.S. patent application Ser. No.14/454,414, filed Aug. 7, 2014, and also claims priority to U.S.Provisional Patent Appln. No. 61/986,997, filed May 1, 2014, the entirecontents of each of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to systems, apparatus, and methods,whereby carbon-based wastes may be converted into (i) high-gradesynthetic crude oil, (ii) synthetic gas (SynGas), and (iii)nitrogen-rich ash fertilizer, and to compositions made thereby. In aparticularly preferred embodiment, the invention relates to theconversion of animal wastes, such as chicken litter, into theabove-noted products in a process that is eco-friendly, can usefeedstock with up to 75% water content, produces essentially no harmfulfugitive emissions, operates at low pressure and at skin temperaturesbelow 140 degrees Fahrenheit (no risk of explosion), requires noheating, cooling, or drying of feedstock, and the reaction isself-sustaining after initial ignition.

2. Description of Related Art

As is known, chicken is a very popular meal in American homes andrestaurants. Increasing sales of chicken products have led to thewide-spread industrial production and processing of chicken stock. In2013, it was estimated that there were more than one billion chickens ineach of Georgia, Arkansas, and Alabama; with Mississippi, NorthCarolina, Texas, and Kentucky not far behind. Of course, such vastnumbers of chickens mean vast amounts of solid waste, termed “chickenlitter”, from the bedding material and from the chickens themselves. Itis estimated that one billion chickens will produce 5500 tons of chickenlitter per day. This is a prodigious amount of solid/liquid waste whichis currently causing severe environmental problems, such as water-tablepollution, methane-gas production, pollution of streams and rivers, etc.The U.S. Environmental Protection Agency has taken steps to amelioratethe disadvantageous environmental effects of chicken litter. See, forexample, EPA Notice EPA 305-F-03-002, April 2003, “Poultry Productionand Environmental Stewardship.”

Some attempts have been made to covert waste, such as chicken litter,into usable energy. As one example, the inventor of the subjectapplication is an inventor of U.S. Pat. No. 7,964,026, issued Jun. 21,2011, and U.S. Pat. No. 8,216,345, issued Jul. 10, 2012 (the entirecontends of each being incorporated herein by reference), which disclosegasification method and apparatus for converting chicken litter into acombustible gas. This was a notable advance in the art, but producedonly gas, while filtering out oil, tar, and other “waste” materials.Thus, much potential energy was lost. Furthermore, it is known thatcombustible gas presents collection and distribution problems,especially in a production model where many such facilities aredistributed over wide areas of agricultural land. Considering theirrelative potential energy, oil is easier to transport than gas.

Now, consider all forms of waste. Waste in all forms is an inevitableproduct and dilemma of modern urban and rural life. Animal waste poses aserious threat to the World's watersheds and serious health risks.Animal waste—chickens, hogs or cattle—is one of the world's greatestthreats to natural habitats, water tables, and the health of theenvironment. It has been estimated that there are approximately 17billion chickens, 1 billion cattle, and 1 billion pigs worldwide thatproduce 13 billion tons of waste each day that must be disposed of. Thegrowth of industrial farming has concentrated thousands of animals onincreasingly fewer farms resulting in enormous amounts of animal wasteon relatively small plots of land increasing the risk of run-off andwatershed damage. Raw animal waste is commonly used as a fertilizer witha drying or curing process that releases methane gas into theatmosphere. Factory farms crowd animals into relatively small areaswhere waste accumulates in massive waste piles or fetid lagoons that canthreaten the health of livestock as well as leak or overflow, sendingdangerous bacteria, phosphorous, and nitrate pollution into watersupplies. Animal waste emits methane that has 25 times the GlobalWarming Potential (GWP) of carbon dioxide

However, the known art described in the above-noted patents still failsto achieve many desired traits. With respect to farm-produced syngas,typical farms could not consume the energy that could be producedthereby, and could not benefit economically from the sale ofelectricity, primarily from the capital cost of the infrastructure.Essentially, from environmental and economic standpoints, the solutionsdid not provide for a net gain to the poultry farm.

SUMMARY OF THE INVENTION

The present invention differentiates from the prior art through, interalia, the generation of an electric current within the reaction chamberby means of a fuel cell-type action. Because of the separation of theash plate from the inner wall section, the addition of cross members tothe inner wall section, and the separate control of the (preferably)three (3) stirring or agitating members, the reaction chamber can becontrolled to produce electric current to enhance the chemicalreactions. The ability to control where the carbonate layer is disposedwithin the reaction chamber, with respect to the fuel stirringdevice(s), allows current to be produced and flow from the chamber innerwall to the stirring shaft through the wetted feedstock between thecross members and the multiple stirring arms, making them act aselectrodes. The prior art '026 patent could not accomplish this, and thefeed stocks were thus subject to combustion reactions only. In the '026patent, the fuel stirrer needed to move more frequently and would removeash as it moved, not allowing time for the formation of a beneficialcarbonate electrolyte layer. The ash layer height can be controlledindependently in the present invention, and with the physical detachmentof the ash plate from the inner wall, the present invention functions asa fuel cell in the lower portion of the inner wall section of thereaction chamber. This generates the electricity needed for much morefruitful chemical reactions to be described below.

The present invention also has secondary applications beyond chickenlitter. For example, feedstock for the present invention can come fromany organic source to include, at least: poultry litter, horse manure,cow manure, shredded tires (with metal), wood waste, switch grass,cafeteria waste, rice hulls, MDF sanding dust (with water added),lignite, gasifier ash and municipal solid waste. Such feedstocks cancontain up to 75 percent by weight of water, thus making available avery wide array of materials for use in the present invention.

It is an advantage of the present invention to overcome the problems ofthe related art and to provide a means to convert what would be wastewater and hazardous organic acids produced by prior art gasifiers andother biomass pyrolysis processes into the potential energy ofhydrocarbon liquids. This provides the means to convert all of themanure and organic waste into an economically viable means of wasteremoval. The present invention also produces gas, which can be used for,e.g., electricity-generation and/or the production of marketablehydrocarbons, while the remaining matter is converted into sellablecrude oil and nitrogen-containing ash fertilizer.

According to a first aspect of the present invention, a novelcombination of structure and/or steps is provided whereby apparatusconverting chicken liter into oil, combustible gas, and ash fertilizerhas a feed stock input configured to receive the chicken liter. Areformer is coupled to the feed stock input and is configured to provideoil, combustible gas, and ash fertilizer outputs. Preferably, thereformer has (i) an outer wall, (ii) a reaction chamber with an innerwall unconnected to the outer wall at an upper portion of the reactionchamber, (iii) a combustible gas input, (iv) a scrubbing liquid input,(v) a fuel stirrer, (vi) an ash stirrer, (vii) an ash plate, (viii) anigniter, and (ix) a combined liquid/gas output. The ash plate iselectrically isolated from the inner wall. An ash output is configuredto output ash from a bottom of the reformer. At least one liquid/gaspump is preferably configured to carry the combined liquid/gas from thereformer liquid/gas output. At least one gas/liquid separator ispreferably configured to receive the liquid/gas output from the at leastone liquid/gas pump, and provide a substantially gas output and asubstantially liquid output. At least one oil/water separator ispreferably configured to receive the substantially liquid output fromthe at least one gas/liquid separator and to provide a substantiallywater output and a substantially oil output. At least one processor isconfigured to control at least the feed stock input, a temperature ofthe reformer, the at least one liquid/gas pump, the at least onegas/liquid separator, and the at least one oil/water separator. The atleast one processor controls the temperature of the reformer so as tocause an electric current to flow upward along the inner wall and inwardtoward heated reaction products within the reaction chamber.

According to a second aspect of the present invention, a novelcombination of structure and/or steps is provided whereby a fuelcell-like structure is formed from the operation and configuration ofthe ash plate and the inner wall of the reaction chamber. This causescurrent flow through the ash layer, under the carbonate electrolytelayer, and arcs due to the size and crystalline structure of the ash.This arcing causes dissociation of incoming molecules, such as nitrogen,hydrogen, etc., into their atomic species. For example, hydrogen isnaturally H₂, a molecule, and by contact with the induced electric arcbecome 2H, an atom. Atoms can have at least a 10 fold increase in thereaction energies over the naturally occurring molecule; this is seen inthe potential energy of output products. Just above the fuel cell layeris a charcoal produced by the heat generated by the less than 100%efficiency of the fuel cell to cause pyrolysis of the feedstock. Thepyrolysis oils and water then rise back up through the section of fuelstirrer arms and inner wall cross members (being electrodes) for theelectrolysis of the pyrolysis oil, water, and injected sludge and waterfrom the oil/water separator, to produce gas, including ammonia, andhydrocarbon liquids.

According to a third aspect of the present invention, a novelcombination of features is provided whereby non-transitorycomputer-readable media is used with at least one processor to controlthe pumps, valves, and motors for the flow of gases, liquids, ash, andfeedstock into and out of the system; to control the frequency and speedof the feedstock leveler and feed auger to maintain proper levels in thesystem; to control of the fuel stirrer(s) to maintain the consistency ofthe feedstock and maximize surface exposure for continuous electrolysisof the water and pyrolysis oils; to control the ash stirrer(s) tomaintain the carbonate electrolyte layer for the generation ofelectricity for the other processes; to control the injection of sludgeand water onto the feedstock to control the temperature and maintain thelayers appropriately for the processes to occur; and to control thequality of the outputs. The at least one processor also controls thevalves for the ash output which, in turn, control the amount of airinput to the system through the ash auger. There are eight or moredevices that are preferably controlled to manage the layers that inducethe processes which produce the products.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the presently preferred features of theinvention will now be described with reference to the accompanyingdrawings.

FIG. 1A is a block diagram of certain of the apparatus according to apreferred embodiment of the present invention; and FIG. 1B is a close-upof the reformer of FIG. 1A.

FIGS. 2A and 2B are, respectively, cross-sectional and top plan views ofthe reaction chamber cross members 4 according to the FIG. 1 embodiment.

FIG. 3 is a top plan view of the ash plate 12 of the FIG. 1 embodiment.

FIG. 4 is a schematic diagram of some of the processes and layers withinthe reaction chamber of the FIG. 1 embodiment.

FIG. 5 is chemical process diagram of the FIG. 1 embodiment.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY EMBODIMENTS 1.Introduction

The present invention will now be described with respect to severalembodiments in which organic feedstock, such as chicken litter, isconverted into refinable oil, combustible gas, and ash fertilizer, usinga very small carbon footprint process and apparatus.

Briefly, the preferred embodiments of the present invention provideapparatus, process, computer-implemented method, and non-transitorycomputer-readable code whereby feedstock, such as chicken litter, isconverted into oil, gas, and fertilizer, solving environmental andenergy problems at once.

Unless otherwise indicated, all numbers expressing dimensions,capacities, and so forth used in the specification and claims are to beunderstood as being modified in all instances by the term “about.”Without limiting the application of the doctrine of equivalents to thescope of the claims, each numerical parameter should at least beconstrued in light of the number of reported significant digits and byapplying ordinary rounding techniques.

The present invention may be practiced by implementing process steps indifferent orders than as specifically set forth herein. All referencesto a “step” may include multiple steps (or substeps) within the meaningof a step. Likewise, all references to “steps” in plural form may alsobe construed as a single process step or various combinations of steps.The present invention may be practiced by implementing process units indifferent orders than as specifically set forth herein. All referencesto a “unit” may include multiple units (or subunits) within the meaningof a unit. Likewise, all references to “units” in plural form may alsobe construed as a single process unit or various combinations of units.

As used in this specification and the appended claims, the singularforms “a,” “an,” and “the” include plural referents unless the contextclearly indicates otherwise.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as is commonly understood by one of ordinary skillin the art to which this invention belongs. If a definition set forth inthis section is contrary to or otherwise inconsistent with a definitionset forth in patents, published patent applications, and otherpublications that are herein incorporated by reference, the definitionset forth in this section prevails over the definition that isincorporated herein by reference.

The term “processor” and “processing structure” as used herein meansprocessing devices, apparatus, programs, circuits, components, systems,and subsystems, whether implemented in hardware, tangibly-embodiedsoftware or both, and whether or not programmable. The term “processor”as used herein includes, but is not limited to, one or more computers,personal computers, CPUs, ASICS, PLC's, hardwired circuits, signalmodifying devices and systems, devices, and machines for controllingsystems, central processing units, programmable devices, and systems,field-programmable gate arrays, application-specific integratedcircuits, systems on a chip, systems comprised of discrete elementsand/or circuits, state machines, virtual machines, data processors,processing facilities, and combinations of any of the foregoing.

The terms “storage” and “data storage” and “memory” as used herein meanone or more non-transitory data storage devices, apparatus, programs,circuits, components, systems, subsystems, locations, and storage mediaserving to retain data, whether on a temporary or permanent basis, andto provide such retained data. The terms “storage” and “data storage” asused herein include, but are not limited to, hard disks, solid statedrives, flash memory, DRAM, RAM, ROM, tape cartridges, and any othermedium capable of storing computer-readable data.

The term “feedstock” shall mean any type of organic material capable ofbeing reduced by the present process to include, but not limited to,materials such as poultry litter, horse manure, cow manure, any type ofanimal waste, shredded tires (with metal), wood waste, switch grass,cafeteria waste, rice hulls, bagasse MDF sanding dust (with wateradded), lignite, gasifier ash, and municipal solid waste.

“Biomass,” for the purposes of the present invention, is any materialnot derived from fossil resources and comprising at least carbon,hydrogen, and oxygen. Biomass includes, for example, plant andplant-derived material, vegetation, agricultural waste, forestry waste,wood waste, paper waste, animal-derived waste, and poultry-derivedwaste. The present invention may also be used for carbon-containingfeedstocks other than biomass, such as a fossil fuel (e.g., coal,petroleum, oil, and tar sands) and municipal solid waste. Thus, anymethod, apparatus, or system described herein in reference to biomasscan alternatively be used with any other feedstock. Also, variousmixtures may be utilized, such as mixtures of biomass and coal.

The methods and systems of the invention can accommodate a wide range offeedstocks of various types, sizes, and moisture contents. In someapproaches of the invention, the biomass feedstock can include one ormore materials selected from timber harvesting residues, softwood chips,hardwood chips, tree branches, tree stumps, leaves, bark, sawdust,off-spec paper pulp, corn, corn stover, wheat straw, rice straw, soybeanstraw, sugarcane bagasse, switch grass, miscanthus, commercial waste,grape pumice, almond shells, pecan shells, coconut shells, coffeegrounds, grass pellets, hay pellets, wood pellets, cardboard, paper,algae, or the torrified version of any biomass materials listed above.Industrial byproducts such as corn fiber from a wet-mill ethanol processor lignin from a cellulosic ethanol plant can also be feed stocks. Aperson of ordinary skill in the art will readily appreciate that thecarbon based feedstock options are virtually unlimited. For example, thepresent invention can process feed stocks with moisture contents of 25percent, 30 percent, 35 percent, 40 percent, 45 percent, 50 percent, 55percent, 60 percent, 65 percent, 70 percent, or even higher.

2. The Structure of the Preferred Embodiments

With reference to FIGS. 1A and 1B, the reformer apparatus 100 includes areformer chamber 110 having a top section 101, a middle section 102, anda lower section 103. Generally, (i) feedstock is introduced into the topof section 102 through, e.g., a feed stock auger 1, (ii) the feedstockis reaction-processed in the section 102 in a manner to be described ingreater detail below, (iii) certain gravity-fed reaction byproducts,such as ash fertilizer, are evacuated through the section 103 via, e.g.,an ash auger 15, and (iv) certain liquid-entrained reaction byproductsare extracted though pipe 10 for production of syngas and oils. Notethat the current reformer is scalable and may be produced inembodiments/units of two ton per day, ten ton per day, fifty ton perday, one hundred ton per day, etc.

The reformer chamber 110 has an outer wall 13 that is preferably made of304 stainless steel or better, and is preferably approximately 4 feet indiameter, ¼″ inches thick walls, and 7½ feet tall. The reformer section101 preferably intakes scrubbing liquid via a line/pipe 6; andrecirculated waters, oils, and sludge through a line/pipe 11, inprocesses to be described further below. The input feedstock and liquidsin the section 101 are preferably gravity-fed to an upper plate 31,which is preferably supported by a donut shaped plate 33 (which may bemade of an electrically and/or thermally insulating material) coupled toan outer cylindrical wall 13. The upper plate 31 is preferablyperforated (in a manner generally similar to the ash plate 12 depictedin FIG. 3; although the holes may be larger to act as a filter and aformer for the input feedstock. For example, the upper plate 31 may haveapproximately 100 holes, each approximately three-quarters of an inch indiameter. In a particularly preferred embodiment, the flanges on thesections 101 and 102 (FIG. 1B) support the upper plate 31, and areseparated by silicon gaskets 312 to effect the desired insulation. Theupper plate 31 and the donut shaped plate 33 hold and combine thefeedstock and liquids so that they are properly formed and filteredbefore they fall into the inner reaction chamber 9 of the section 102,helped by at least one rotating leveling arm 2, preferably disposedabove the upper plate 31 (but at least one such leveling arm 2 could bedisposed below the plate 31). For some feedstocks which are morehomogeneous in size (such as some types of chicken litter), the upperplate 31 is not necessary, and the donut shaped plate 33 and theleveling arm 2 can provide acceptable dispersal of the feedstock intothe reaction chamber. In this configuration, input liquid from line 11would be mixed with the feedstock on the donut shaped plate 33.

The reformer 110 has an inner cylindrical wall 3, which forms a reactionchamber 9 in conjunction with the upper plate 31 at the top, and an ashplate 12 at the bottom thereof. Preferably, the inner wall 3 is made ofa 310 or better stainless steel, is 3.6 feet in diameter, 0.5 inchthick, and 1.5 feet tall. Preferably, the ash plate 12 is supported byanother donut-shaped plate 66 (which may be segmented in sections andwhich may be supported an electrical and/or thermal insulator, such as asilicon gasket 612—also segmented). The ash plate 12 (FIG. 3) can be ofthe same design as the upper plate 31, or a different design, dependingon the particular type of feedstock being used. In the most preferredembodiment, for chicken litter, the ash plate 12 has approximately 200holes, each approximately one half inch in diameter. The ash plate 12 ispreferably supported by the donut-shaped plate 66 or by brackets withinthe outer wall, and preferably is separated from the inner wall 3, sothat ash can spill over its entire circumference, through the segmentsin plate 66 and gasket 612.

Within the reaction chamber 9 are disposed plural cross members 4 (seeFIGS. 2A and 2B), which act to break up any feedstock, ash, and/orpartially-combusted products, to provide complete reaction pyrolysis,and to produce a fine ash. Cross members 4 are preferably attachedacross the inner wall 3 above and below each arm of the fuel stirrerarms 7, making sure there is no contact with the fuel stirrer arms 7.Preferably, the cross members 4 are welded to the outside and to theinside of the inner wall 3 where they pass therethrough, to prevent gasleakage. These cross members 4 are preferably made of chrome alloy steeland preferably are chrome-plated. Additionally, the cross members 4 arepreferably staggered around the circumference so no two members are inalignment. See FIGS. 2A and 2B.

Also within the reaction chamber 9, and interlaced with the crossmembers 4 (see FIG. 1B), are (i) at least one (for chicken litter,preferably five) one-arm, rotating fuel stirrer arms 7, and (ii) atleast one one-arm, rotating ash stirrer arm 5. These stirrers also actto keep the feedstock and pyrolysis reaction products agitated forbetter surface contact ignition and more efficient production of theoil, gas, and ash. Preferably, the multiple fuel stirrer arms 7 areevenly staggered about their axis of rotation, when viewed from above.Of course, the leveling arm 2, the fuel arms 7, and the ash arm 5 mayeach comprise one or more arms, which may rotate, vibrate, and/orreciprocate, as desired. While these arms may be driven by a commonmotor, in the preferred embodiment each is driven by its own separatemotor and may be driven to move in multiple directions.

The reformer (inner) reaction chamber 9 also has a gas input line 20,which may come from a propane tank 22, and/or be coupled to a syntheticgas line 325. An igniter 24 (e.g., a spark plug) is preferably coupledto the gas input line 20, and acts to ignite propane in the gas inputline 20, which is fed to a burner 217 (preferably disposed beneath thelower ash plate 12) to begin the combustion process to initiate thereactions within the chamber. The burner 217 may comprise a simpletwo-arm burner with twenty-four gas holes in each arm, or a circularburner with a similar number of holes. Preferably, the ignited gas isdistributed upward into the reaction chamber through holes 212 in thelower ash plate 12 (FIG. 3). After combustion has reached apredetermined target (or threshold), such as 150 degrees F. (as detectedby a thermostat inside the reaction chamber 9 coupled to one or morecontrol processors 410), the input gas line 20 is then fed with therecirculated synthetic gas produced by the reaction/reformation processto be described below, via line 325; and propane from the tank 22 isturned off, for example with valve 201. The ash produced by the processto be described below falls through the reaction chamber 9, is agitatedby the ash stirrer 5, and then falls over the circumference of the ashplate 12 (and/or through holes/slots therein), through to a bottom ashplate 8, which is preferably the bottom of the lower section 103 wherethe ash auger 15 is preferably mounted. The ash is then swept into theash auger 15 with at least one lower ash stirrer 81 (FIG. 1B) which maybe disposed above or below the bottom ash plate 8; and the ash is thenexhausted through an ash output 151 into, preferably, a barrel or otherreceptacle. The at least one lower ash stirrer 81 preferably has fourstirring arms, and the bottom ash plate 8 is preferably at least equalin diameter to the outer wall 13. The bottom ash plate 8 preferably iscircular-shaped and has a generally rectangular shaped slot thereindisposed over the top of ash auger 15. The top and bottom edges of therectangular slot are preferably curved with a similar diameter as theoutside of the ash plate 8, to enhance movement of the ash into the ashauger 15.

The other usable (combustible) products are preferably extracted fromthe reformer 110 as a gas/liquid mixture via exit piping 10 from the topsection 101, after being mixed with scrubbing water introduced via thescrubbing water input line 6. Preferably, the scrubbing line 6 isdisposed directly above the intake of the output line 10. Preferably,two gas/liquid blowers or pumps 14 take the liquid/gas output from theoutput piping 10 and provide it to the gas/liquid separator 17.Preferably, each blower comprises a 25 GPM, 800 CFM @ 50 ft. of headgas/liquid pump. These blowers thus form a vacuum or low pressure volumeinside the top section 101 of the reformer 110, which aids in theformation of beneficial hydrocarbon gasses/liquids, as will be describedin greater detail below.

The gas/liquid separator 17 then separates the gas products from theliquid products, and provides some of the liquid via line 321 to thescrubbing liquid line 6, for reintroduction into the top section 101 ofthe reformer 110. Gas products from the gas/liquid separator 17 arepreferably output via the synthetic gas line 32, which gas may be (i)re-used via the gas input line 325, and/or (ii) be used as an energysource for other processes such as electricity generation, heating,conversions to liquid carbons (Gas To Liquids), etc., and/or (iii)merely flamed as waste. Liquid from the bottom of the gas/liquidseparator 17 is extracted via a liquid line 322, preferably boosted by apump 323, and provided to the oil/water separator 16 via line 324.

The oil/water separator 16 separates the oil from the water and providesthe refinable oil through oil output line 444. Water is preferablyoutput from the side of the oil/water separator 16 via line 161 (whichmay have a floating output valve) to a scrubbing liquid pump 162 fortransmission to the scrubbing liquid line 6. Heavier separated oils,tars, sludge, etc., are preferably taken from the bottom of theoil/water separator 16 via line 169 via pump 163, and sent back to thereformer 110 via line 11.

Control of the process is preferably achieved by at least one processor410 connected to the various components via wires (some of which areshown in FIG. 1A) and/or wireless means. The at least one processor maycomprise a personal computer, one or more special purpose processors,hardware, and/or firmware, etc. The at least one processor 410preferably contains program code which, when loaded into and run by theat least one processor, causes the at least one processor to execute thefunctions described herein and those typical functions necessary orconvenient to support the described functions. The at least oneprocessor 410 preferably controls the entire process by controlling thevarious motors, pumps, augers, valves, etc. to be described below.

The feedstock auger 1 introduces feedstock into the reformer at a ratecontrolled by a feedstock auger motor 111, as controlled by the at leastone processor 410. The one or more fuel stirrers 7, the one or more ashstirrers 5, and one or more leveling arms 2 are controlled by a commonmotor (or individual motors) 711, as controlled by the at least oneprocessor 410. The igniter 24 and an input gas line valve 201 are alsocontrolled by the at least one processor 410, as is the ash auger 15 viaash auger motor 152. The rate at which the gas/liquid reaction productsare removed from the reformer is controlled, inter alia, by the speedand torque of the respective motors of blowers 14. Likewise, theoperations of the pumps 162, 163, and 323 are also controlled by the atleast one processor 410. Further, each of lines/pipes depicted anddescribed herein may have one or more valves a, b, c, d, e, f, g, h, i,j, k, l, m and n to control flow in their respective lines, as eitheron/off, multiple outputs, and/or restricted flow, depending on the needsof the process, as controlled by the at least one processor 410. Theconnections from the at least one processor to the above-noted valvesare not depicted in FIG. 1A for clarity, although those connections maybe wired or wireless, depending on the installation. As one exampleonly, process parameters which have been successfully tested with thepreferred embodiment include: control of the syngas out of system tocontrol the flow of synthesis gas back to the reformer through the flowcontrol valve a, preferably controlled by one or more oxygen sensors Qin the syngas output line 32. The scrubbing liquid 6 and bottoms return11 are preferably controlled by variable speed motors in pumps 162 and163, preferably controlled by one or more emulsion level control devices168 in the oil/water separator 16.

FIGS. 2A and 2B depict a preferred structure of cross members 4 disposedin the reaction chamber 9. FIG. 2A is a plan view of the cross members4, which are, preferably, interspersed with respect to the one or morefuel stirrers 7 and the one or more ash stirrers 5. FIG. 2B is a topview of the cross members 4, showing the preferred crossing patternsdesigned to break up and homogenize the various layers of pyrolysisreaction products within the reaction chamber 9. Preferably, each crossmember 4 is made of 4140 chrome plated steel or better, and is 3.6 feetlong, 1 inch wide, and 1 inch thick.

FIG. 3 is a top plan view of the ash plate 12, showing an outer patternof through-holes 211, and a different inner pattern of through-holes212. A central hole 213 allows for passage of the support shaft of thefuel and ash stirrers. Preferably, the ash plate 12 is made of 304stainless steel or better, is 448 inches in diameter, and is ⅝ inchesthick. The bottom ash plate 8 may be of a similar design, or differentdesign, as deemed appropriate for each application. As noted above, thebottom ash plate 8 preferably has a 12 inch by 3 inch opening on oneside of the central hole 213, above where the ash auger 15 is mounted.The ash stirrer 8 sweeps ash that has fallen by gravity into ash auger15.

3. The Functions of the Preferred Embodiments

FIG. 4 is a schematic functional block diagram of the various layers andprocesses which take place inside the reaction chamber 9 of the reformer110. These layers are preferably formed as a single stack of layerswhich may or may not have clearly defined boundaries between the layers.As described above, feedstock 511 (wetted to perhaps 50 percent withrecirculated sludge, and/or scrubber liquid, and/or its own compounds)is preferably introduced into reformer section 101 at ambienttemperature or the temperature of the oil/water separator 16 (e.g.,125-130 degrees F.). The feedstock 511 is preferably combusted/processedin the electrolysis layer 611 (to cause pyrolysis), in the charcoallayer 712, in the carbonate plasma layer 811, and in the ash layer 911,in a manner to be described below. In each layer, solid mineral carbonsmigrate downward due to the force of gravity, as assisted by thestirrers, to the ash plate 12 where they will exit the reaction chamber9 as ash. At the same time, useful oils and gasses migrate upwardthrough the layers to the reformer upper section 101, where at leastsome of the oils boil off under the vacuum (or partial vacuum) createdby blowers 14. The remaining oils, the migrated gasses, and theboiled-off-oil gasses are the useful hydrocarbon products which are thenmixed with scrubbing water as described above, and they are thenevacuated via reformer output piping 10. The scrubbing water thusentrains certain of the useful gasses and oils, and also acts to keepthe feedstock at a desired wetting level.

The above described reaction pyrolysis takes place in the reactionchamber 9 using either input gas (such as propane) via piping 20, orrecirculated synthetic gas produced by the reformer itself via piping325. In the electrolysis layer 611, the heat from the inefficiencies ofa fuel cell process in the carbonate layer reaction causes the feedstock511 to produce pyrolysis oils. The electrolysis layer 611 also producesuseful hydrocarbons, paraffins, olefins, alcohols, and/or carbon dioxidewhich are products of a process known as Kolbe Electrolysis. Theseproducts are produced at the anode while hydrogen is evolved at thecathode, as will be described below. Decane and pentane, for example,are the predominant products from caproic acid, a common pyrolysisproduct. Other hydrocarbon products will depend on the feedstock, asdifferent organic acids will evolve from the different materials. Theelectrolysis layer 611 typically ranges from about 350 degrees F. at thetop thereof to about 900 degrees F. at the charcoal layer 712. Theelectrolysis layer 611 comprises oils, water, and wetted feedstock (fromthe pyrolysis oils typically produced at temperatures of 730 degrees F.and higher near the charcoal layer), and water and oils injected at line6 and the water content of the feedstock itself, where some of the oilsare from the lower layers.

Gravity and the stirrers gradually force reaction products from theelectrolysis layer 611 downward into the charcoal layer 712, where theproducts more closely resemble charcoal at about 900-1800 degrees F.Like in the electrolysis layer 611, in the charcoal layer 712 carbonminerals migrate downward while useful oils and gasses migrate upward.Gas molecules such as syngas, and air introduced below the ash plate 12(through the ash auger mechanism 15) and dissociated in the ash layer911, react with the carbon in the charcoal layer 712 to produce some ofthe gases and oils that rise through the electrolysis layer 611.

The carbonate plasma layer 811 is where the hottest temperatures occur,producing a plasma at about 3500 degrees F. As with the charcoal layer712, in the carbonate plasma layer 811, minerals migrate downward asthey react to form crystalline solids, while useful oils and gassesmigrate upward. This electrolyte (the natural mineral carbonates of thefeedstock, or one or more catalysts that may be added to the feedstock)causes the transfer of electrons from incoming gases (e.g., syn gas),making it act like a fuel cell and providing the electric current usedin the arcing in ash layer 911 below and in the charcoal layer 712 aboveand in the electrolysis layer 611. Preferably, the current generatedwould be about 600 amperes or higher, at a voltage of 8000 VDC orhigher.

As the lower layers finish combustion, they produce an ash layer 911,which is perhaps 140 degrees F., and is eventually evacuated from thereformer through the bottom ash plate 8 using gravity and the ash auger15, as described above. The incoming gases (air from below and gas frominput line 20 and/or 325) are heated and dissociated in this layer asdescribed below. The ash stirrer 5 helps keep the ash crushed to cause(i) the interstitial spaces preferable for arcing and (ii) movement ofthe ash over the outer perimeter of the ash plate 12. Note that whilethe temperatures inside the reaction chamber 9 may be quite high, theouter skin temperature of outer wall 13 rarely exceeds 140 degrees F.The vacuum (or low pressure) space between the inner wall 3 and theouter wall 13 insulates against the hotter inner chamber temperatures.

A preferred feature of the present invention is the “arcing andsparking” which preferably takes place predominantly in the carbonateplasma layer 811 and in the ash layer 911. This arcing and/or sparkingcauses the disassociation of hydrogen, nitrogen, and oxygen moleculesinto atoms, thus releasing much more energy, as will be described ingreater detail below. See, for example, U.S. Pat. No. 4,472,172 toSheer, et al., the entire contents of which are incorporated herein byreference. The present invention preferably makes use of an electricalcurrent flow set in the reaction chamber 9 to cause this arcing and/orsparking. With reference to the arrows in FIG. 4, the source ofelectrical energy is mostly in the carbonate plasma layer where carbonis separated from oxygen, producing electrons from the oxygen (see alsoFIG. 5); which electrons flow upward along metal inner wall 3. Since theinner wall 3 is electrically isolated from the outer wall 13, and sincethe electrolysis layer 611 is somewhat wetted, this layer attracts thecurrent flowing in the inner wall 3. Electricity follows the path ofleast resistance, Ohms Law, and the electrical resistance to the metalin the outer wall 13 is higher than the wetted carbon materials in theelectrolysis layer 611. Additionally, the liquids pumped back into thereformer through line 6 will contain certain salts that increase theelectrical conductivity of the wetted area and act as an electrolyte forthe electrolysis. The mineral content of the carbon layer increases downthrough the charcoal layer 712, which increases the resistance, aidingin the current flow up the inner wall 3 and across to the layer 611.Thereafter, the current is attracted downward through the layers 712 and811 to the ash layer 911 and the metal ash plate 12. It is thispotential difference within the layers that causes the arcing andsparking which provides the increased energy by disassociation ofhydrogen and oxygen molecules, aided by the fact that the ash plate 12is preferably not electrically coupled to the inner wall 3 (or has arelatively low conductance). Furthermore, the current flow may causepyrolysis oils (which are produced in the electrolysis layer 611 asdescribed above) to also produce hydrocarbons from the top of thecharcoal layer 712 via the process of Kolbe Electrolysis as they move upthrough the electrolysis layer 611.

FIG. 5 schematically depicts the electro-chemical processes of a directcarbon fuel cell, formed in the present invention. The electrolyteincludes at least the carbonate from the mineral content of thefeedstock. The cathode includes at least the fuel stirrer(s) 7, the ashplate 12, and the ash layer 911. The anode includes at least the innerwall 3 and the cross members 4. Chemically, the oxygen gives up two (2)electrons at the electrolyte, i.e. the naturally occurring carbonates,which pass to the inner wall 3 and return to the cathode. This makes thereaction of carbon and oxygen result in carbon dioxide found in the gas.The same reaction may occur with hydrogen and nitrogen resulting inhydrocarbons as well as ammonia and amines, for example. In greaterdetail, FIG. 5 shows how the separation of the reactants carbon andoxygen, for example, produce electric current when separated by anelectrolyte. Preferably, the electrolyte is a carbonate or moltencarbonate. As air enters from ash auger 15 and reaches the electrolytelayer, electrons are released from each oxygen molecule, which electronspass through the inner wall 3 and cross members 4. As with allelectrical circuits, there has to be a completion through a load for theflow of current to occur. Here the current passes from the electrolytelayer 611, preferably being a portion of the load, and into the fuelstirrers 7. Current then moves down through fuel stirrer 7, to the ashlayer 911, and ash plate 12, and back to the beginning of theelectrolyte layer to complete the circuit. The current flow through theash layer 911 causes the arcing and sparking described above, which canalso be referred to as short circuiting. The oxygen ions now passthrough the electrolyte layer to chemically react with the carbon toproduce carbon dioxide, for example.

To provide greater detail to the above brief description of theprocesses within reaction chamber 9, the process by which the preferredembodiments utilize electrolysis of pyrolysis to reform synthesis gasinto liquid will now be described. In the lower portion of the section102 of the reformer, electrical generation is accomplished, at least inpart, by the application of a direct carbon fuel cell, e.g., asdescribed in U.S. Pat. No. 7,438,987 to Cooper, the entire contents ofwhich are incorporated herein by reference. The direct carbon fuel cellis first used to ionize gases produced (or in the processes of beingproduced) in sections 101, 102, and 103, and returned to below the ashplate 12 via piping 32 and 20 and passed through the holes 212 of FIG. 3to produce chemical reactions between carbon, the synthesis gas, andwithin the synthesis gas itself. See FIG. 5 for an illustration of theoperation of a direct carbon fuel cell. Oxygen from the air that entersthrough ash auger 15 reacts with carbon to form carbon dioxide. Whenthis reaction occurs, heat is produced, e.g., a fire in the fire place.However, in this and other fuel cell arrangements, the oxygen isseparated from the carbon by an electrolyte. Oxygen has to give off twoelectrons to react with carbon, see FIG. 5. In a fire place, theseelectrons cause heat. In the reaction chamber 9, the electrons arein-part transferred by the electrolyte to the inner wall 3 producingsome electric current rather than all heat. Electrons that do not getconducted as current cause the heat that produces the pyrolysis at thecharcoal layer 712. The oxygen/carbon reaction is one example of areaction that can occur in this layer.

Referring again to FIG. 5, in the preferred embodiments, the cathode 51(including the fuel stirrer(s)) is extended through the anode 52(including the inner wall 3). The current is produced, in part, by airintroduced by induced draft through the ash auger 15, caused by theblowers 14 bringing in air through the ash auger 15 to provide oxygenfrom that air and around the outside edge of the ash plate 12 and to thecarbonate electrolyte layer 811, to produce the current by the oxygenchemical reaction described above and illustrated in FIG. 5. Theseparation of carbon from the ash plate 12 as current collector (andfrom the ash) by an electrolyte 53 (being carbonates and other materialin the feedstock in the carbonate plasma layer 811), causes theformation of ions in an aqueous solution, including but not limited tomolten materials (e.g., plasma). Such electrolyte materials may include,but are not limited to, sodium, potassium, and other transition metalhydroxides, carbonates, and salts that naturally occur in biomass.

As the ash layer 911 is cooled into a crystalline structure by incomingsynthesis gas and air (from, e.g., the ash outlet 151), it is referredto as ash and can be part of the cathode 51, along with the ash plate12. Incoming air and synthesis gas are kept somewhat separate by fillingthe center portion of the ash plate 12 with gas, causing the air, inlarge part, to move up the outer wall 13 and through the gap between theinner wall 3 and the ash plate 12. Any ash that fuses or bonds togetherabove or below the electrolyte 53 zone is broken and/or crushed by thestirring arms of the ash stirrer 5 and/or the fuel stirrers 7. The toparm of the ash stirrer 5 is preferably disposed above the ash plate 12,and is preferably operated in conjunction with another ash arm 81(FIG. 1) disposed below the ash plate 8 to remove ash, as needed, tocontrol the position of electrolyte 53 within the inner wall 3 ofsection 102 of the reformer.

Preferably, the ash plate 12 and the ash stirrer 5 are isolated from theinner wall 3, creating an electrical potential difference between theinner wall 3 and the fuel stirrers 7, and completing the electricalcircuit through the feedstock material 511 and its constituents as it isreduced. Due to the higher resistance of the metal in the inner wall 3,the outer wall 13, and the fuel stirrer 7, the current will flow throughthe carbon, ash, and wet materials (layers 511, 611, 712, 811, and 911of FIG. 4), is the path of least resistance.

The ash plate 12 is preferably supported by the outer wall 13 from belowvia the donut-shaped porous plate 66 or brackets (which may beelectrically and/or thermally insulated from the outer wall) to allowash to be removed over the entire periphery of the plate 12. The ashplate 12 is preferably larger in diameter than the inner wall 3 tomaintain the ash level to a controlled depth so that ash is removed asneeded rather than falling in an uncontrolled fashion. As the ashstirrer 5 is rotated, the circumferential gap between the ash plate 12and the inner wall 3, and the inner wall cross members 4 act together tocrush and/or break any fused ash or ash stuck together by other means,thus keeping the ash size appropriate in optimizing the arcingpreferably used in the ionization of incoming synthesis gas.

The gas-to-liquids conversion, being a reaction between hydrogen andcarbon, or hydrogen and nitrogen, for example, in the lower portion ofsection 102 preferably uses the conductivity, size, consistency, andmovement of the ash to cause arcing, also referred to as sparks, betweenpieces of ash as they move. These arcs ionize components of thesynthesis gas, known as dissociation from molecules into atoms. Arcingis considered the most efficient means of molecular dissociation but maynot be the only means. Based on the Gibbs free energy equation (G(T,p)=U+pV−TS; where U is the internal energy in joules, p is pressure, Vis volume in meters cubed, T is the temperature, and S is the entropy injoules per Kelvin) and reaction kinetics, the enthalpy, entropy, andfree energy of the reaction for gas-to-liquids is dramatically increasedover and above traditionally known gas-to-liquid operations, such as,but not limited to, Fischer-Tropsch and Haber-Bosch for reactions tooccur near or below atmospheric pressure. The discovery that H atomsreact with carbon spontaneously, instantaneously, and at low pressure,forming hydrocarbons was made by Avramenko in 1946. He passed hydrogengas through an arc chamber then onto a carbon disk producinghydrocarbons at near-atmospheric pressures. His work used an externalelectrical energy input into the system where as the process accordingto the present invention preferably uses electrical energy generated bythe system itself.

Other means of internal electrical power generation used in the presentinvention could include (but not be limited to) magnetohydrodynamics(MHD), pyroelectric electric, piezoelectric electric and ferroelectricelectric effects. MHD is the flow of electrically conductive gases suchas, but not limited to, hydrogen through a magnetic field in the innerwall 3 of section 102. The current flow in the inner wall 3 from otherelectrical effects of the ash from heat, pressure of the stirring arms,and/or the weight of material above the ash produces a magnetic field.The gas flow would be seeded by the carbonates, salts, and otherelectrically conductive materials in the ash. Other possible means ofcurrent flow in the inner wall could be, but are not limited to, theSeebeck Effect. Thomas Johann Seebeck first discovered the effect in1821 which is a means of converting heat into electrical energy. Becausethese effects are traditionally static electricity, the arrangement ofthe fuel stirrer 7, the ash stirrer 5, the ash plate 12, and the innerwall 3 cause a potential difference for the electrical energy to be usedfor chemical reactions within the reactor rather than removed from thesystem and used externally.

The resulting reactions produce complex compounds. Reactions betweenhydrogen and carbon tend to yield aromatic hydrocarbons. Nitrogen andhydrogen can also yield ammonia. Ammonia reacts with aromatichydrocarbons to produce primary, secondary, and tertiary amines. All ofwhich have been found by analysis of the output oil, as will be detailedbelow.

Another compound found in the output oil is phenol, also found bychemical analysis (discussed below). The process for making phenolsbegins with aromatic hydrocarbons such as isopropyl benzene which isreacted with an alkaline such as caustic, carbonate or bicarbonate. Theproduct of this reaction is phenol and acetone, which appear in the oilanalysis as well.

The combined electrical effects, the inefficiencies, and the alternatingfrequency caused by current arcing in the ash produce direct heat aswell as induction heating in section 102 for the purpose of pyrolysis ofthe incoming feedstock. The products of the pyrolysis undergo Kolbeelectrolysis, the electro-chemical conversion of organic acids tohydrocarbons. See, for example, U.S. Pat. No. 6,238,543, to Law, Jr.,the entire contents of which are incorporated herein by reference.Various factors such as temperature, current density, electrodematerial, and electrolyte material affect the hydrocarbon productiondistribution. Studies indicate that low temperature and low currentdensity with nickel or nickel alloy metal cathodes with platinum orchromium anodes (preferably used in the present invention) have betteryield percentages. The reformer construction according to the presentinvention preferably uses nickel alloy, or better, in the fuel stirrerarms 7; having multiple arms attached to a central rotatable shaft andstaggered around the center shaft as they move down; making sure that nopart of the stirrer assembly comes into contact with the inner wall 3.

Electrolysis of acids to produce hydrocarbons has been studied for morethan 200 years with many questions as to the exact mechanism oroperating conditions. Rheinold and Erman were the first to investigateelectricity as a potential oxidizing or reducing agent in aqueoussolutions of alcohol. In 1830, Ludersdorff undertook the first detailedstudies of products using various electrode materials. Kolbe made hisbreakthrough studies in 1845. To make the most of the conditionsnecessary for electrolysis, all of the conditions are at least partiallycontrollable in the preferred embodiments. Temperature may be controlledby injection of liquid from the oil/water separation tank 16 and/or theamount and velocity of the feed gas. The bottom layers in tank 16 (whereheavy liquids and tars, for example, collect) may be pumped back intothe top of section 101 onto the feedstock 511, via line 11. Suchtank-bottom sludge may be pumped back not only for temperature control,but for the reforming of those components as well. The output from tank16 to line 161 may be made height-adjustable for different feed stocksand/or process speeds. Liquid from the tank 16 layer above the bottomlayers is preferably pumped back to section 101 via line 6 for bothtemperature control and scrubbing as the gas/liquid output from thereactor passes through the piping 10 and the blowers 14, as it is movedto the gas/liquid separator/scrubber 17. As described above, inside thereaction chamber 9, current density is passed through the risingpyrolysis oil as it moves through the cross members 4. Controlling thefrequency and the speed of the rotation of the fuel stirrer arms 7causes current to be at least partially consumed by electrolysis of thepyrolysis oils. Electrode material has already been discussed above.Electrolyte material is a natural component of the feedstock, but couldbe altered by addition of other catalytic materials, if needed.

The pyrolysis of the feedstock mostly occurs near the charcoal layer 712lower in the inner wall section above ash plate 12 and the ash layer 911(the fuel cell area). Production of organic acids, acetic acid, andother acidic material is well known in pyrolysis. Here, by placing theblowers 14 to pull from the reformer, a vacuum (or partial-vacuum)pyrolysis process is set up. Typically, temperatures of 730 degrees F.to 932 degrees F. are required for the reaction to occur. The top thirdof the inner wall section (reaction chamber 9) is preferably controlledto be around 350 degrees F. to around 425 degrees F. Because of thistemperature control, the produced pyrolysis oils rise up through theelectrolysis section 611 of the reaction chamber 9. Compounds such asacetic acid coming in contact with the entering feed stock assists inthe pyrolysis. This process is known as acid hydrolysis. Studies haveshown that pretreatment of biomass by a mild acid hydrolysis to removehemicellusose followed by pyrolysis causes a higher yield of fermentablesugars. Pentose and hexose, for example, from acid hydrolysis blend withanhydro sugars customarily recovered from pyrolysis. These studies havealso shown a decrease in the amount of water from vacuum pyrolysis afterpretreatment and the increase of levoglucasan, for example, and adecrease in xylan. Xylan has been shown to be a primary contributor tothe formation of tars in the pyrolysis process. Because the pyrolysisoccurs below the feedstock and rises back up, it pretreats the incomingfeedstock.

As noted above, wetting of the feedstock is an advantageous featureaccording to the preferred embodiments, allowing for a broader range offeedstock materials, and producing more useful products. The wetting ispreferably an internal process. At the top of the carbon layer, wherethe fuel cell process occurs, is where the pyrolysis preferably occurs.The pyrolysis oils rise back through the feedstock causing some of thewetting. Acetic acid is used to wet material for pyrolysis and is anatural component of pyrolysis. The acetic acid is broken down in theelectrolysis. Also, pumping of the bottoms from the oil/water separator16 is a wetting process, and providing these to the feedstock throughpipes 6 and 11 assists in controlling the wetness of the feedstock.Supplemental wetting of the feedstock may be used outside the reformerto add moisture if the material is too dry. For example, some kiln driedmaterials may have water added to bring the feedstock moisture contentup to 50% or so.

As also noted above, the leveling arm 2 is used in section 101 to sweepthe feedstock material from under the feed auger 1 to bring the materialinto the reformation chamber and to maintain an even bed height. Theauger 1 is preferably fed through an airlock system 113 (FIG. 1B) toprevent substantial amounts of air from entering the section 101 anddamaging the vacuum (or partial vacuum) therein; and air trapped in thechambers of the air lock 113 is preferably removed using the vacuum ofthe lower section 103 below the ash support 8, which is connected to theouter wall 13 of the reformer.

4. In Operation

In operation, the at least one processor 410 controls the variousaugers, valves, blowers, pumps, and motors as described below.Preferably, the structures are controlled to feed approximately 0.25 to10 tons of chicken litter per day into the reformer. This will typicallyproduce approximately: 2 to 100 pounds per hour of ash fertilizer(depending on the mineral content of the feedstock; e.g., pine is 0.25%,rice straw is 12%); 3 to 150 gallons of oil per hour; and 1,200 to48,000 cubic feet of syngas per hour.

Once the reformer unit is fully started with feedstock entering thereformer and the propane gas ignited and being fed to the reactionchamber 9, the propane flow is kept at a level where the fire preferablystays toward the bottom of the inner reaction chamber 9. The temperatureof the outer wall 13 is monitored (e.g., with one or morethermocouples), and when the return synthetic gas becomes combustible(e.g., the combustion reaches a threshold such as, 150 degrees F.) theburner is turned off, the air inlet on the burner is closed, and thereturn synthetic gas flow to the burner tube is opened. When the ashlayer 911 preferably reaches 2 to 4 inches (preferable maximum for thecurrent embodiments) the hydrogen rich syngas flowing upward through theash produces first a pyroelectric charge which will discharge as anelectric arc in hydrogen which has a conductivity of 187 mW/m-K comparedto air at 26.2 mW/m-K. This arcing between the pieces of ash causes thehydrogen to dissociate, leading to the reaction example 8H+3C→C₃H₈,thermodynamically resulting in 1848 KJ of energy release compared to agasification reaction of the same amount of carbon (3C+2O2→2CO+CO₂) at614.5 KJ. This makes the reaction according to the present invention atleast 3 times that of the prior art energy release, and an energycontent comparison output at 5 time that of gasifiers. The hydrogenconversion rate is about 60% to 70%.

Other thermal and kinetic energy conversion methods may includepiezoelectric, ferroelectric, and MHD power generation produced by theflow of the conductive hydrogen through an electric field produced bycurrent flow through the chamber walls. Another consideration would be afuel cell, solid oxide to be specific. The combustion of hydrogen andoxygen in the ash, or oxide, would produce electric charge, and justlike a fuel cell, would arc between pieces like cracks and fissures (oneof the inefficiencies). These same inefficiencies are problems in fuelcells, MHD, and would be in pyroelectric generators. But it is thisinefficiency that is taken advantage of in the reformer according to thepresent invention.

It is well worth noting that the arcing dissociates nitrogen, oxygen,and most any diatomic molecule from the air. The disassociation ofnitrogen is a strong indication of the nitrogen found in the ashaccording to the present invention. These same arcs comprise plasmaelectrolysis which has been reported in hydrogen production from waterat 80 times that of the Faraday current prediction. The most acceptedexplanation is thermal decomposition. All of the thermoelectricconversion methods, as well as kinetic conversion methods, have theconditions to produce current and voltage at varying degrees. It is thiscombination that is most likely providing the beneficial resultsaccording to the present invention.

Once reaction from the starting (ignition) process has produced a layerof ash 911, above this a (at least partially) static plasma zone formsin the layer of ash; and charcoal 712 or carbonate 811 would be the morelikely zone(s) for the magneto-hydrodynamic conversion of the kineticmotion of synthesis gas (primarily hydrogen for the conversion) within amagnetic field to produce the electricity. Charge produced in the ash,once the ash has reached the bottom of the inner reactor 9, would travelup the reactor wall 3 and produce the magnetic field, as noted above.Though it is not considered to be highly energetic, it is expected to beoccurring. Current produced by this MHD generator would also travelpredominantly through the carbon, causing electrolysis to occur, withcarbon being one electrode and minerals in the biomass feedstock beingthe other. Hydrogen itself could act as the negative electrode andreduce both free water and hygroscopic water. This process occurs,producing synthesis gas, until the carbonate layer 811 moves high enoughso that the current can move through the inner wall 3 and ash layer 911to begin the other processes.

Another reaction that occurs in the reformer is hydro-treating of thepyrolysis oils. Heat generated from the formation of hydrocarbons in thediminishing zones of ash 911 and carbon 811 pyrolizes the incomingbiomass where light oils are removed by boiling at low pressures in theupper section 101. Heavy oils will move down through the bed whereatomic hydrogen will hydrotreat this oil. See, for example, thecatalytic process for the treatment of organic compounds discussed inU.S. Pat. No. 7,387,712, the entire contents of which are incorporatedherein by reference. A process for the catalytic reaction of organiccompounds is provided, in which the organic compounds are contacted witha catalyst comprising an interstitial metal hydride (having a reactionsurface) to produce a catalyst-organic compound mixture; energy isapplied, monatomic hydrogen is produced at the reaction surface of theinterstitial metal hydride, and the organic compounds are reacted withthe monatomic hydrogen. Reactions accomplished by this process includepetroleum hydrocracking and hydrotreating processes. “Interstitial”means the small spaces within the material, and metal hydrides arematerials that can form from the mineral content of the feedstock. Whensteam reacts with carbon, it will form carbon monoxide and hydrogen.Momentarily, hydrogen will exist as monatomic, i.e. an atom, while it isproduced in the presence organic compounds produced within the process,this reaction can occur.

5. Results

Initial tests with chicken litter have been very impressive. The presentinvention provides 10× waste matter conversion efficiency vs. existingtechnology of gasification or pyrolysis. The present invention tolerateswater content in the feedstock of up to 75 percent by weight vs. 15percent by weight maximum water content for existing technologies.Feedstock with a water content of 15 to 50 percent is presentlypreferred for use in the present invention. This means that mostcontemplated feed stocks do not have to undergo a pre-process dryingstep. The present invention may process any carbon-based wet waste, suchas animal waste, biomass, municipal solid waste, etc. The processoutputs are (i) semi-refined petroleum high in aromatics with little orno sulfur, (ii) synthesis gas having a hydrogen to CO Ratio of about2.2:1, and (iii) fertilizer ash high in nutritional value foragriculture. Notably, the present process generates very little or noharmful fugitive emissions. In addition, the present invention is quitegreen in that it helps the environment. It is well known that animalwaste emits methane with 25× the global warming potential of CO₂. Forexample, 100 tons of chicken litter per day has the same yearly globalwarming potential impact as burning >30,000,000 gallons of gasoline.Thus, the present invention removes harmful substances from theenvironment. Further, the ash fertilizer according to the presentinvention may be stored and transported more economically, and providesnutritional value with none of the chemical or biological risksassociated with using raw chicken litter as fertilizer.

The present invention is thus an internally-regenerated, high-energy,sustained reaction process that converts carbon based feed stocks intorefinable hydrocarbons and other compounds that can be used to producevaluable fuel, chemical byproducts, and energetic gas. An externallygenerated high-temperature plasma field converts the feed stocks intotheir simplest molecules—hydrogen, carbon monoxide, and other compounds,forming a synthetic gaseous mixture that may be used to generateelectricity and/or produce valuable fuel and chemical byproducts.Pyrolysis preferably heats the waste in an oxygen-deprived environment,where material combusts to produce heat, carbon dioxide, and a varietyof oleo chemicals.

As one example, a 10-15 tons of chicken litter feedstock per dayreformer according to the present invention produces 60 barrels ofsemi-refined petroleum per day (24,000 barrels per year); 0.33 tons ofash fertilizer per day (100 tons per year); and 633,600 cubic feet ofsynthetic gas per day (215,424,0000 cubic feet per year) withrecirculation of the gas and based on 340 days per year operation. Thisremoves much harmful material from the environment, provides largequantities of diverse energy, and causes little or no pollution by theprocess.

ARK GAS™. A comparison of the synthetic gas provided by the presentinvention (termed ARK GAS™) with gas produced by typical gasifiersreveals that the syn gas according to the present invention has a uniquechemical signature having, for example, over 2× more hydrogen, which maybe used to generate electrical power and/or in high value chemicals viacatalysts or bio-digesters. See Tables 1 and 2 below.

TABLE 1 Comparison of Typical Syngas with ARK GAS ™ Gasifier PresentInvention Mole % Mole % Hydrogen 22.32 47.68 Nitrogen 25.98 Methane 0.90Carbon Monoxide 40.81 18.35 Ethane 0.18 Water 24.29 0.44

TABLE 2 Comparison of Typical Syngas with ARK GAS ™ Present GasifierInvention Feedstock H₂O Limit 15% 75% Pure Oxygen Required Yes NoPressure As High As Low 600 psi 15 psi Output Temperature >1000° F.<140° F. Explosion Risk Yes No Water Cooling Required Yes No HarmfulEmissions Yes No Output - Present Invention SynGas H:CO Ratio 1:2 2:1Solid Output Molten Slag Fertilizer Present Invention Semi-refinedPetroleum No Yes

Chemical analyses of the unique signature of the syn gas produced inaccordance with the present invention is set forth below in Tables 3, 4,5, and 6.

TABLE 3 COMPONENTS METHOD# MOLE % LIQ. VOL % WEIGHT % Hydrogen D-1945-8147.681 40.654 5.825 Nitrogen D-1945-81 25.982 27.030 44.106 MethaneD-1945-81 0.905 1.455 0.880 Carbon Monoxide D-1945-81 16.350 19.57231.147 CO2 D-1945-81 6.320 10.221 16.855 Ethane D-1945-81 0.182 0.4620.332 Water D-1945-81 0.439 0.238 0.479 Propane D-1945-82 0.141 0.3690.377 Isobutane D-1945-81 0.000 0.000 0.000 n-Butane D-1945-81 0.0000.000 0.000 Isopentane D-1945-81 0.000 0.000 0.000 n-Pentane D-1945-810.000 0.000 0.000 Hazanes+ D-1945-81 0.000 0.000 0.000 Totals 100.000100.000 100.000

TABLE 4 Calculated Values: MOLECULAR WEIGHT 16.502 HEATING VALUEBTUGI/DSCF @ 14.696 psia & 60° F. = 170.71 HEATING VALUE BTUGI/DSCF @14.73 psia & 60° F. = 171.10 HEATING VALUE BTUNI/DSCF @ 14.696 psia &60° F. = 206.38 COMPRESSIBILITY FACTOR @ 14.696 psia & 60° F. = 0.99053RELATIVE DENSITY @ 14.696 psia & 60° F. = 0.7367

TABLE 5 COMPONENTS METHOD# MOLE % LIQ. VOL % WEIGHT % Hydrogen D-1945-8179.134 68.553 16.804 Air O2 & N2 D-1945-81 5.020 5.306 14.813 MethaneD-1945-81 1.313 2.145 2.219 Carbon D-1945-81 0.273 0.296 0.805 CO2D-1945-81 13.425 22.059 62.235 Ethane D-1945-81 0.216 0.557 0.684Unsaturated D-1945-81 0.413 0.536 1.483 Propane D-1945-81 0.206 0.5470.957 Isobutane D-1945-81 0.000 0.000 0.000 n-Butans D-1945-81 0.0000.000 0.000 Isopentane D-1945-81 0.000 0.000 0.000 n-Pentane D-1945-810.000 0.000 0.000 Hazanes+ D-1945-81 0.000 0.000 0.000 Totals METHOD#100.000 100.000 100.000

TABLE 6 MOLECULAR WEIGHT 9.494 ISENTROPIC FACTOR, k @ 14.696 psia & &60° F. 1.3823 MOLAR MASS RATIO @ 16.696 psia & & 60° F. 0.32779 HEATINGVALUE BTUGI/DSCF @ 14.696 psia & & 60° F. 282.33 HEATING VALUEBTUGI/DSCF @ 14.73 psia & & 60° F. 282.98 HEATING VALUE BTUNI/DSCF @14.696 psia & & 60° F. 240.17 VISCOSITY centipoise |(g)| @ 14.696 psia && 60° F. 0.01384 SPECIFIC HEAT BTU/lbm* ‘F @ 14.696 psia & & 60° F.0.75639 COMPRESSIBILITY FACTOR @ 14.696 psia & & 60° F. 0.99791

Since the syn gas according to the present invention has high hydrogencontent (preferably above 35 mole percent, more preferably above 40 molepercent, even more preferably above 45 mole percent), it can be used fora wide variety of applications. It can be used in a boiler to generateelectricity, and/or in a power generator to power a gas turbine and/orfuel cells. The hydrogen may be extracted to be used in refineryhydrotreating, transportation fuels, and/or fertilizers. Likewise,methanol may be extracted and used to produce formaldehyde, methylacetate, acetic anhydride, acetic acid, vinyl acetate monomer, polyvinylacetate, ketene, diketeme and derivatives, ethylene propolene,polyolefins, oxy chemicals, dimethyl ether, gasoline, Fischer-Tropshmaterials, wax, diesel/kerosene, naptha, and/or ethanol. Moreover, thereforming apparatus according to the present invention uses a geographicfootprint of only 12 feet long, 8 feet wide, 7 feet high, which is much,much less that the footprint of a typical multi-acre gasification plant.Note that the syngas according to the present invention has very lowamounts of methane (preferably less than about 5 mole percent, morepreferably less than about 3 mole percent, even more preferably lessthan about 1 mole percent). The Hydrogen will preferably be in the rangeof 30 to 80 mole percent, more preferably, 35 to 70 mole percent, evenmore preferably, 40 to 60 mole percent, yet more preferably, 43 to 55mole percent, even more preferably, 45 to 50 mole percent, mostpreferably, 47.69 mole percent. The Nitrogen will preferably be in therange of 4 to 40 mole percent, more preferably, 10 to 37 mole percent,even more preferably, 15 to 34 mole percent, yet more preferably, 20 to32 mole percent, even more preferably, 23 to 30 mole percent, mostpreferably, 25.98 mole percent. The Methane will preferably be in therange of 0.1 to 2 mole percent, more preferably, 0.2 to 1.8 molepercent, even more preferably, 0.3 to 1.5 mole percent, yet morepreferably, 0.6 to 1.2 mole percent, even more preferably, 0.8 to 1.0mole percent, most preferably, 0.9 mole percent. The Carbon Monoxidewill preferably be in the range of 6 to 25 mole percent, morepreferably, 10 to 23 mole percent, even more preferably, 13 to 21 molepercent, yet more preferably, 15 to 20 mole percent, even morepreferably, 17 to 19 mole percent, most preferably, 18.35 mole percent.The Ethane will preferably be in the range of 0 to 1 mole percent, morepreferably, 0.03 to 0.7 mole percent, even more preferably, 0.05 to 0.5mole percent, yet more preferably, 0.07 to 0.4 mole percent, even morepreferably, 0.1 to 0.3 mole percent, most preferably, 0.18 mole percent.The water will preferably be in the range of 0 to 1 mole percent, morepreferably, 0.1 to 0.8 mole percent, even more preferably, 0.2 to 0.7mole percent, yet more preferably, 0.3 to 0.6 mole percent, even morepreferably, 0.4 to 0.5 mole percent, most preferably, 0.44 mole percent.

ARK OIL™. The oil produced by the present invention (termed ARK OIL™) isan engineered petroleum product valuable as produced (semi-refined) orwith further refining. This oil has a unique signature making itsuitable for a wide variety of useful applications. A CompositionBreakdown Gas Chromatography/Mass Spectrometry, per ASTM 05739 wasconducted on the chicken-litter oil product in January 2014. The samplewas analyzed on a gas chromatograph/mass spectrometer. A library searchwas performed on the collected data using the Wiley 138 Library and theNIST 98 Library. Together the libraries contain approximately 200,000compounds. The top layer of the sample was analyzed as received. Thesedata are based on the chromatographable components found. If heaviercompounds or polymers were present they were not seen on the gaschromatograph/mass spectrometer. No corrections for the inorganiccontent, if present, or water content was performed. The identities andapproximate concentrations that follow are based on the best spectralcomparisons from the libraries and the total ion relative areas of thepeaks observed. The material found consists primarily of light tri- andtetramethyl-benzenes and lesser amounts alkyl-naphthalene compounds.Lesser amounts of other organic compounds were also observed, which werecomprised of indenes, saturates, olefins, ketones, amines, acids,alcohols, aldehydes, esters and other oxygenated compounds. Theapproximate concentration and organic chemical types are as follows:

TABLE 7 Approximate Concentration Tentatively Identifed Ratios Relativeto Extractables Compounds Found Percent by Weight Isoparaffins 0.7Nanhthenics 0.5 Mono-aromatics mostly trimethyl benzenes 65.7Di-aromatics 18.5 Poly-aromatics 2.4 Acids other carboxylic acids 0.8Alcohols 0.4 Aldehydes 0.2 Amines and other nitrogen containing 1.3compounds Esters (organic acid esters) 0.8 Indenes 3.2 Ketones 0.7Olefins 1.1 Other low level organic compounds 3.7 Total 100.

TABLE 8 Density of Petroleum Products, Hydrometer, 0.9543 ASTM D1298.g/cm³ @ 60° F. API Gravity @ 60° F. 16.63

A similar analysis was undertaken, but without the use of thecross-members 4 in the reaction chamber 9. The results are shown inTable 9.

TABLE 9 Approximate Tentatively Identifed Quantification Compounds FoundPercent by Weight Normal paraffins 3.7 Iso paraffins 11.4 Cyclicparaffins (naphthenes) 24.4 Mono aromatics (including alkyl benzenes)0.9 Di aromatics (including alkyl naphthalenes) 3.6 Poly aromatics(including alkyl poly 1.6 aromatics) Organic acids 2.4 Alcohols 8.8Aldehydes 0.2 Amides 1.9 Amines and other heterocyclics 3.4 Esters (acidesters and phthalate esters) 0.5 Indenes 2.9 Ketones 3.7 Olefins 11.0Phenolics 2.9 Organo nitrites 2.6 Halogen containing organics 5.8Oxygenates 0.8 Others 7.5 Total 100.0

Experiments show that most feed stocks used in the present inventionwill produce useful oils having approximately the following make-upshown in Table 10.

TABLE 10 Compounds Percent By Weight isoparaffins 0.2 to 15.0naphthenics 0.1 to 15.0 mono-aromatics 3.0 to 75.0 di-aromatics   0 to40.0 poly-aromatics   0 to 15.0 acids 0.1 to 3.0 alcohols   0 to 15.0aldehydes 0.1 to 3.0 amines 0.1 to 7.0 esters 0.1 to 3.0 indenes 0.1 to7.0 ketones 0.1 to 7.0 olefins 0.1 to 30.0 low level organic compounds0.1 to 11.0

Thus, the preferred embodiments can provide an oil made of pyrolysiscompounds that have undergone electrolysis, and compounds made in anelectric arc gas to liquids process. The composition of the feedstock isbelieved to be the principle driver (not exclusive) to the paraffin andolefins content. Inefficiencies in this electrolysis process may yieldalcohols, acids, phenols, and nitriles. The gas-to-liquids operation ofthe electric arc process described above produces aromatics, amines,amides, ketones, indenes; the composition of each depends on the amountof gas converted in electric arc gas to liquids. The isoparaffins willpreferably be in the range of 0.2 to 15 percent by weight, morepreferably, 0.3 to 10 percent by weight, even more preferably, 0.4 to 7percent by weight, yet more preferably, 0.5 to 4 percent by weight, evenmore preferably, 0.6 to 1 percent by weight, most preferably, 0.7percent by weight. The naphthenics will preferably be in the range of0.1 to 15 percent by weight, more preferably, 0.2 to 10 percent byweight, even more preferably, 0.3 to 5 percent by weight, yet morepreferably, 0.4 to 1 percent by weight, most preferably, 0.5 percent byweight. The mono-aromatics will preferably be in the range of 3 to 75percent by weight, more preferably, 10 to 73 percent by weight, evenmore preferably, 30 to 71 percent by weight, yet more preferably, 50 to69 percent by weight, even more preferably, 60 to 67 percent by weight,most preferably, 65 percent by weight. The di-aromatics will preferablybe in the range of 0 to 40 percent by weight, more preferably, 5 to 35percent by weight, even more preferably, 10 to 30 percent by weight, yetmore preferably, 12 to 25 percent by weight, even more preferably, 14 to20 percent by weight, most preferably, 18 percent by weight. Thepoly-aromatics will preferably be in the range of 0 to 15 percent byweight, more preferably, 0.5 to 10 percent by weight, even morepreferably, 1 to 7 percent by weight, yet more preferably, 1.5 to 4percent by weight, even more preferably, 2 to 3 percent by weight, mostpreferably, 2.4 percent by weight. The alcohols will preferably be inthe range of 0 to 15 percent by weight, more preferably, 0.1 to 10percent by weight, even more preferably, 0.2 to 5 percent by weight, yetmore preferably, 0.3 to 2 percent by weight, most preferably, 0.4percent by weight. The aldehydes will preferably be in the range of 0.1to 3 percent by weight, more preferably, 0.3 to 10 percent by weight,even more preferably, 0.4 to 7 percent by weight, yet more preferably,0.5 to 4 percent by weight, even more preferably, 0.6 to 1 percent byweight, most preferably, 0.7 percent by weight. The amines willpreferably be in the range of 0.1 to 7 percent by weight, morepreferably, 0.4 to 5 percent by weight, even more preferably, 0.7 to 3percent by weight, yet more preferably, 1.0 to 2 percent by weight, evenmore preferably, 1.1 to 1.5 percent by weight, most preferably, 1.3percent by weight. The esters will preferably be in the range of 0.1 to3 percent by weight, more preferably, 0.3 to 2.5 percent by weight, evenmore preferably, 0.5 to 2 percent by weight, yet more preferably, 0.6 to1.5 percent by weight, even more preferably, 0.7 to 1 percent by weight,most preferably, 0.8 percent by weight. The indenes will preferably bein the range of 0.1 to 7 percent by weight, more preferably, 0.5 to 6percent by weight, even more preferably, 1 to 5 percent by weight, yetmore preferably, 1.5 to 4.5 percent by weight, even more preferably, 2to 4 percent by weight, most preferably, 3.2 percent by weight. Theketones will preferably be in the range of 0.1 to 7 percent by weight,more preferably, 0.2 to 6 percent by weight, even more preferably, 0.3to 5 percent by weight, yet more preferably, 0.4 to 3 percent by weight,even more preferably, 0.5 to 1 percent by weight, most preferably, 0.7percent by weight. The olefins will preferably be in the range of 0.1 to30 percent by weight, more preferably, 0.4 to 20 percent by weight, evenmore preferably, 0.6 to 10 percent by weight, yet more preferably, 0.8to 5 percent by weight, even more preferably, 0.9 to 2 percent byweight, most preferably, 1.1 percent by weight.

The oil according to the preferred embodiments thus shows a uniquemixture of highly complex compounds not typically found in natural crudeoil or products such as Fischer-Tropsch oils, but has compounds that arecommonly man-made. Notably missing from the analysis, or only in smallquantities, are organic acids seen in pyrolysis oils, such aslevoglucasan and acetic acid, and xylan.

The properties of the thus-produced ARK OIL™ may be adjusted by addingcertain additives to the waste litter before pyrolysis. Additivesinclude Arnosoak, a proprietary litter amending agent, and/or woodshavings. The amount of Arnosoak incorporated into litter may be fromabout 0.1% to about 40% by weight of the dry litter, more preferablyfrom about 1% to about 20% by weight of the dry litter. Thus, Arnosoakmay be used to control the pH of the oil. The pH of the untreated oilmay range from 6 to 8, but with the addition of Arnosoak, the pH rangeof the oil can reduced to as low as 4 depending on the amount ofArnosoak added to the litter before the pyrolysis. Adding a solvent tothe oil may be provided for better storage. In certain embodiments, thesolvent added to the oil is ethanol, methanol, acetone, or water. Whenadded, the solvents may be added at a concentration of about 1% to about10% by weight of the oil, with a preferred concentration of 10% byweight of the oil.

ARK SOIL™. The ash fertilizer produced in accordance with the presentinvention (termed ARK SOIL™) also has a unique signature making itattractive as an all-purpose organic fertilizer. This ash fertilizerwill reduce the transported volume and transportation costs associatedwith animal waste used as fertilizer. The ash fertilizer according tothe present invention contains similar nutritional value foragricultural crops without any biological and chemical threats posed bythe raw waste. An analysis of the fertilizer was conducted by theAgricultural Diagnostics Laboratory of the University of Arkansas atFayetteville, with results shown below in Table 11. Other analyses ofARK SOIL™ have shown carbon content of 46 percent. Preferably, thefertilizer according to the present invention will have a high Nitrogencontent, in the range of 0.1 to 3 percent by weight, more preferably,0.3 to 5 percent by weight, even more preferably, 0.6 to 4 percent byweight, yet more preferably, 0.8 to 3 percent by weight, even morepreferably, 1 to 2 percent by weight, most preferably, 1.2 percent byweight.

TABLE 11 Procedure: Digestion with EPA Method 3050 digestion —HNO3/HCI,analysis by N/C by combustion Lab. No. M60993-rep 1 M60993-rep 2M60993-rep3 Sample No. ash ash ash Manure type ash ash ash *Total onas-received basis Total % N 1.21 1.21 1.01 Total % Carbon 12.85 12.9111.04 Total % P 4.90 5.42 5.17 Total % K 8.44 8.55 7.92 Total % Ca 6.938.17 7.59 Total % Mg 1.70 1.7 1.67 Total % S 1.10 1.17 1.15 Na, mg/kg20890 21070 21080 Fe, mg/kg 9000 9180 13590 Mn, mg/kg 1486 1486 1454 Zn,mg/kg 1473 1519 1402 Cu, mg/kg 1122 1026 1065 B, mg/kg 125 119.6 118NOS—N, mg/kg 20 only 1 rep run only 1 rep run NH4—N, mg/kg 24 only 1 reprun only 1 rep run Arsenic, mg/Kg 51 45 49 Cadmium, mg/Kg 2 2.7 2Chromium, mg/Kg 20 25.9 19 Nickel, mg/Kg 38 41.6 38 Lead, mg/Kg 9 10.710 Tot Diss. P, mg/Kg 1031 1110.0 1131 lbs/ton on “as-is” basis Total N24.20 24.2 20.20 Total Carbon 257.00 258.2 220.8 Total P 98.00 108.4103.4 Total K 168.80 171.0 158.4 Total Ca 138.60 163.4 151.8 Total Mg34.00 34.4 33.4 Total S 22.00 23.40 23.00 Total Na 41.76 42.1 42.2 TotalFe 18.00 18.4 27.2 Total Mn 2.97 3.0 2.9 Total Zn 2.95 3.0 2.8 Total Cu2.24 2.1 2.1 Total B 0.25 0.2 0.2 NO3—N 0.04 NH4—N 0.05 Total Arsenic0.100 0.090 0.100 Total Cadmium 0.004 0.005 0.004 Total Chromium 0.0410.052 0.039 Total Nickel 0.076 0.083 0.076 Total Lead 0.018 0.021 0.020Total Diss P 2.1 2.2 2.3

Mass-energy balance studies have been performed on the presentinvention, with the results shown below in Table 12.

TABLE 12 Mass & Energy Balance NH3 In 17.85 Sludge In 3.05 Return Gas150.75 Input Air Input 71.00 Lbs/Hr Litter Input 83.3333 Lbs/Hr Water Wt% in 40% 0 Lbs/Hr Litter Sub Total 325.98 Minus Ash Output 16.58 Lbs/HrOil Output 77.03 Lbs/Hr 15.05 Gal/Hr Gas Output 205.16 Lbs/Hr 44.215SCFM NH3 Out 10.85 Water Output 15 Lbs/Hr Residual Gas 1.36 Lbs/Hr Out325.98 Mass Balance 0.00 Combustion Syngas 44.215 SCFM 642,002 NH3 * H2O6.14 SCFM 172,967 Residual 0.02 SCFM 3,138 Overall Gas 50 SCFM Flow Rate818,107 N2 in Sludge 2.14 H2 in 0.06 O2 in 0.28 C in 0.33 Ammonia 10.85Lb/Hr Sludge Sludge Sludge Out N2 in 39.57 H2 in 13.18 O2 in 35.61 C in62.39 Return Gas return gas return return Gas Gas N2 in Oil 26.87 H2 inOil 6.88 O2 Oil 8.15 Cin 39.48 Gas N2 in Gas 90.4195 H2 in Gas 11.94 O229.85 C in 35.13 Ammonia 17.85 Water Oil in Return Gas N2 in Biomass20.95 H2 in 3.73 O2 Gas 62.40 Combustion 172,967 Btu/Hr Water N2 in Ash0.78 H2 in Air 0.98 O2 from 4.97 Carbon 13. 93 Water in 15 Lb/Hr Biomassin NH4OH Litter 88.17 23.53 105.38 Sludge % 18.6 Air Flow 14.66 In SCFMH2 in 1.98 Return 18.00 3.10 Biomass Gas Flow SCFM Input H2 O2 Carbon N2Output H2 O2 Carbon Nitrogen Dry biomass 1.98 4.97 13.93 20.95 Oil 6.888.15 35.13 26.87 Water 3.73 29.85 0.00 0.00 Gas 11.94 62.40 39.4890.4195 Air 0.98 17.92 0.00 52.54 Water 1.64 13.11 0.00 0 Return Gas13.18 35.61 62.39 39.57 Ash 0.65 4.69 1.72 1.53365 NH3 3.1416 14.7084NH3 1.91 8.9404 Sludge 0.06 0.28 0.33 2.14 Sludge 0.06 0.28 0.33 2.14Total 23.07 88.63 76.65 129.90 23.07 88.63 76.65 129.90 Minus Balance0.00 0.00 0.00 0.00 Energy Balance Btu/Lb Total Exothermic NH3 9,675.8172,713.03 Produced C10H22 4,263.0 262,706.71 CO2 3,847.5 132,938.73 CO1,697.8 108,136.87 Alcohol 3,206.0 21,732.62 H2O 7,605.00 151,859.11850,087.06 Endothermic Consumed Heating Water 1,080.00 36,269.99 HeatingAir 265.90 18,878.48 Decomposition 7,605.00 255,403.70 of Water WaterGas/Lb 21,016.00 395,906.13 H2 706,458.29 Den Mole Wt % Lb/gal Component% Weight % Normal 3.7 5.38 Hydrogen 47.681 5.820323581 paraffinsNitrogen 25.982 44.0747598 iso paraffins 11.4 5.38 Methane 0.9050.879004837 cyclo paraffins 24.4 5.38 Carbon 18.305 31.04517334 monoaromatics 0.9 6.5 Monoxide di aromatics 3.6 6.5 Carbon 6.32 16.84145828poly aromatics 1.6 6.5 Dioxide organic acids 2.4 8.62 Ethane 0.1820.331339134 alcohols 8.8 6.5 Water 0.439 0.478888205 aldehydes 0.2 6.56Propane 0.141 0.376435141 amides 1.9 9.66 Butane 0.045 0.152617678amines 3.4 8.42 Pentane 0 0 esters 0.5 8.16 Acetaldehyde 0 0 indenes 2.98.53 Acetone 0 0 ketones 3.7 6.58 Amylene 0 0 olefins 11 5.17Cyclopentadiene 0 0 phenolics 2.9 8.5 Cyclopentane 0 0 organo nitriles2.6 6.75 Diethylamine 0 0 halogen 5.8 8.6 Ether 0 0 containing Furfuran0 0 organics Neo- 0 0 oxygenates 0.8 6.23 hexane others 7.5 5.78Isoprene 0 0 100 Methyl 0 0 formate Methyial 0 0 Propylamine 0 0Propylamine(i) 0 0 Propylene 0 0 oxide 100 100

Experiments show that the reformer of the present invention may provideoutput as follows: 2000 pounds of feedstock (1 ton) will produceapproximately 6.4 barrels of oil plus approximately 63,000 Cubic feet ofsynthesis gas plus approximately 60 pounds of ash fertilizer.Essentially, one 5 gallon bucket of chicken litter will produce one 5gallon bucket of oil (in addition to the gas and fertilizer).

6. Conclusion

Thus, the present reformer technology reforms any carbon-based wastematerial at the atomic level to produce a high volume of partiallyrefined petroleum (with little or no sulfur), a hydrogen rich synthesisgas, and a solid ash that is classified as a fertilizer by the USDepartment of Agriculture. There are little to no harmful fugitiveemissions. The technology is a fraction of the size and cost of existingwaste-to-energy or waste-to-fuel technologies, and produces a muchhigher volume of valuable energy commodities. The subject reformertechnology provides a low pressure, low-heat, continuous process thatseparates and reforms basic organic elements found in waste materialinto high value partially refined petroleum. The oil productionfacilities according to the present invention have intrinsically lowoperating costs, low capital costs, and high efficiency. Each reformercan provide the most economical method of transforming common organicmaterial into valuable hydrocarbons that are refinery ready, have ahydrogen to carbon monoxide ratio of about 2.2:1, and have minimal or nosulfur. Feedstock conversion efficiency for 100 tons of feedstockproduces more value than 1000 tons processed by existing gasification orpyrolysis technologies. Poultry litter, horse manure, cow manure,shredded tires, wood waste, switch grass, cafeteria waste, rice hulls,Medium-density fibreboard (MDF) sanding dust (with water added),lignite, gasifier ash, and municipal solid waste can be used as afeedstock for the reformer of the present invention successfully.Further, various feedstocks may be combined in various percentages inorder to provide even more engineered oils, gasses, and fertilizers. Itis estimated that the cost of producing a barrel of oil according to thepresent invention will be about $20-25 dollars US, which compares veryfavorably with other forms of oil production. The present inventionproduces hydrocarbons, such as aliphatics, paraffins, aromatics,specialty chemicals, fuel, and fuel & oil additives. The synthetic crudeoil according to the preferred embodiments contains virtually no sulfur.

The individual components shown in outline or designated by blocks inthe attached Drawings are all well-known in the gasification/refiningarts, and their specific construction and operation are not critical tothe operation or best mode for carrying out the invention.

While the present invention has been described with respect to what ispresently considered to be the preferred embodiments, it is to beunderstood that the invention is not limited to the disclosedembodiments. To the contrary, the invention is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims. The scope of the following claims is to beaccorded the broadest interpretation so as to encompass all suchmodifications and equivalent structures and functions.

All U.S. and foreign patents and patent applications discussed above arehereby incorporated by reference into the Detailed Description of thePreferred Embodiments.

What is claimed is:
 1. A method of producing oil, gas, and ash from afeedstock, comprising steps of: inputting the feedstock into a reactionchamber having a wall; combusting the feedstock in the reaction chamber;inducing an electrical current flow inside the reaction chamber, betweenthe reaction chamber wall and the feedstock so as to cause arcing in thefeedstock within the reaction chamber; causing ash reaction byproductsto migrate downward through the reaction chamber to ash supportstructure which is substantially electrically isolated from the reactionchamber wall; causing gas and liquid reaction byproducts to migrateupward through the reaction chamber to an upper chamber; evacuatinggas/liquid products, including the migrated gas and liquid reactionbyproducts, from the upper chamber; and separating oil and gas from theevacuated gas/liquid products.
 2. The method according to claim 1,wherein the steps are controlled by at least one processor.
 3. Themethod according to claim 1, wherein at least a portion of the inputstep is performed by an input auger inputting the feedstock into theupper chamber.
 4. The method according to claim 1, wherein at least aportion of the combusting step includes the steps of (i) providing astored gas to a burner disposed below the ash support structure, (ii)igniting the stored gas emanating from the burner, and (iii) at apredetermined threshold, ceasing the provision of the stored gas andbeginning supplying recirculated syngas to the burner.
 5. A method ofproducing oil, gas, and ash from a feedstock, comprising steps of:inputting the feedstock into a reaction chamber having a wall;combusting the feedstock in the reaction chamber; inducing an electricalcurrent flow, between the reaction chamber wall and the feedstock so asto cause arcing in the feedstock within the reaction chamber; causingash reaction byproducts to migrate downward through the reaction chamberto ash support structure which is substantially electrically isolatedfrom the reaction chamber wall; causing gas and liquid reactionbyproducts to migrate upward through the reaction chamber to an upperchamber; evacuating gas/liquid products, including the migrated gas andliquid reaction byproducts, from the upper chamber; and separating oiland gas from the evacuated gas/liquid products, wherein at least aportion of the inducing step includes inducing the electrical current toflow (i) upward along the reaction chamber wall and into an upper layerof the feedstock within the reaction chamber, and (ii) downward througha fuel stirrer toward the ash support.
 6. The method according to claim1, wherein at least a portion of the step of causing the gas and liquidreaction byproducts to migrate upward includes the step of forming atleast a partial vacuum in the upper chamber.
 7. The method according toclaim 6, wherein at least one gas/liquid pump is used to perform atleast a portion of the steps (i) causing the gas and liquid reactionbyproducts to migrate upward, and (ii) evacuating the gas/liquidproducts from the upper chamber.
 8. The method according to claim 1,wherein the separating step produces an oil comprising, substantially:0.2 to 15.0 percent by weight isoparaffins; 0.1 to 15.0 percent byweight naphthenics; 3.0 to 75.0 percent by weight mono-aromatics; 0 to40.0 percent by weight di-aromatics; 0 to 15.0 percent by weightpoly-aromatics; 0.1 to 3.0 percent by weight acids; 0 to 15.0 percent byweight alcohols; 0.1 to 3.0 percent by weight aldehydes; 0.1 to 7.0percent by weight amines; 0.1 to 3.0 percent by weight esters; 0.1 to7.0 percent by weight indenes; 0.1 to 7.0 percent by weight ketones; 0.1to 30.0 percent by weight olefins; and 0.1 to 11.0 percent by weight lowlevel organic compounds.
 9. The method according to claim 1, wherein theseparating step produces an oil comprising, substantially 75 percentaromatics.
 10. The method according to claim 1, further comprising:stirring products within the reaction chamber with at least one stirringelement; and separating the products within the reaction chamber usingplural cross members coupled to the reaction chamber wall, wherein thecross members are electrically isolated from the at least one stirringelement.
 11. The method according to claim 1, further comprising forminglayers within the reaction chamber that comprise: a feedstock layer, anelectrolysis layer, a charcoal layer, a carbonate layer, and an ashlayer.
 12. The method according to claim 11, wherein the carbonate layerincludes a plasma zone.
 13. The method according to claim 1, wherein thestep of causing gas and liquid reaction byproducts to migrate upwardincludes the step of using evacuation structure to provide at least apartial vacuum in the upper chamber, providing an upward airflow frombelow the ash support structure up to the evacuation structure.
 14. Amethod of producing oil, gas, and ash from a feedstock, comprising stepsof: controlling speeds of a feedstock leveler and a feed auger, tomaintain a predetermined level of feedstock in a reaction chamber havinga wall; controlling a speed of at least one fuel stirrer to (i) maintainsubstantial consistency of the feedstock in the reaction chamber, (ii)maximize surface exposure for substantially continuous electrolysis ofwater and pyrolysis oils in the feedstock, and (iii) maintain acarbonate electrolyte layer for the generation of arcing within thefeedstock; controlling injection of sludge and water onto the feedstockto (i) control the temperature in the reaction chamber and (ii) maintainreaction chamber layers for pyrolysis to occur; and controlling a levelof ash on an ash support below the reaction chamber to control theamount of air input to the system through an ash auger.
 15. The methodaccording to claim 14, wherein water content of the feedstock is greaterthan about 15 percent by weight.
 16. The method according to claim 14,wherein the hydrogen-to-carbon monoxide ratio of output gas issubstantially 2.2-to-1.
 17. The method according to claim 14, furthercomprising inducing a current flow in the chamber wall to cause arcingof the material in the combustion chamber.
 18. The method according toclaim 14, wherein a current flow is induced in the reaction chamber, atleast in part, by providing a potential difference between the chamberwall and an ash plate disposed below the reaction chamber.
 19. Themethod according to claim 14, wherein a current flow is induced in thereaction chamber, in part, by providing a potential difference between afuel stirrer disposed in the reaction chamber and plural cross membersdisposed in the reaction chamber and in contact with the reactionchamber wall.
 20. The method according to claim 14, further comprisingstirring the materials within the reaction chamber with at least onefuel stirrer.
 21. A method of reforming a feedstock into oil, gas, andash fertilizer, comprising steps of: feeding the feedstock into a topportion of a reformer; feeding liquid into the reformer top portion towet the feedstock; providing the wetted feedstock to a reaction chamberinside a reformer portion below the top portion; combusting/reacting thewetted feedstock in the reaction chamber; inducing an electrical currentto flow upward along a wall of the reaction chamber and into a topportion of the wetted feedstock, to cause arcing of products within thereaction chamber; introducing air to a bottom of the reaction chamber;evacuating hydrocarbon byproducts of the reaction inside the reactionchamber by forming a partial vacuum in the reformer top portion, thepartial vacuum and the air introduction causing an upward airflow in thereaction chamber; evacuating the ash fertilizer from the bottom of thereaction chamber; separating the evacuated hydrocarbon byproducts intogas and oil/liquid; separating the oil/liquid into oil and liquid;recirculating at least a portion of the separated gas to the combustingstep; and recirculating at least a portion of the separated liquid tothe feeding liquid step.
 22. An oil product produced by the processaccording to claim
 1. 23. An ash fertilizer product produced by theprocess according to claim
 1. 24. A gas product produced by the processaccording to claim
 1. 25. An oil product produced by the processaccording to claim
 14. 26. An ash fertilizer product produced by theprocess according to claim
 14. 27. A gas product produced by the processaccording to claim
 14. 28. An oil product produced by the processaccording to claim
 21. 29. An ash fertilizer product produced by theprocess according to claim
 21. 30. A gas product produced by the processaccording to claim 21.